Medical Cartridge Receiver Having Access Device

ABSTRACT

A needle and receiver assembly for use with a syringe cartridge filled with medicine includes a cartridge receiver having a hollow interior, an open end sized for receiving at least part of the syringe cartridge, and a closed end opposite the open end. The assembly includes a needle mounted on the receiver having a fluid passage extending between a sharp delivery tip at a distal end of the needle and a sharp access tip at a proximal end of the needle opposite the delivery tip positioned inside the hollow interior of the receiver. The assembly includes a cutter movably mounted in the hollow interior of the receiver for cutting the diaphragm of the cartridge when received in the hollow interior of the receiver.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patent application Ser. No. 13/438,854, filed on Apr. 4, 2012, which will issue as U.S. Pat. No. 8,864,719 on Oct. 21, 2014, and which claims the priority of U.S. patent application Ser. No. 61/471,909, filed Apr. 5, 2011, both of which are hereby incorporated by reference in their entirety.

BACKGROUND

The present invention generally relates to syringes for injecting liquid medications from prefilled cartridges, and more particularly to a cartridge receiver having a cutter for preparing a cartridge diaphragm.

Local anesthetic is frequently used to numb tissue in a patient's mouth to reduce pain and discomfort a patient may feel during a dental procedure. Conventionally, a reusable syringe assembly is used to inject the anesthetic or medicine from a cartridge or carpule. The cartridge is a glass cylinder containing a local anesthetic and other ingredients. A diaphragm at one end of the cylinder is held in place by an aluminum band. The opposite end of the cylinder has a moveable piston or stopper. The syringe assembly includes a barrel for receiving the cartridge, a plunger rod slidably received in a proximal end of the barrel for actuating the cartridge, an access needle at a distal end of the barrel for puncturing the diaphragm, and a delivery needle connected to the access needle for delivering anesthetic to the patient. In some cases, the plunger rod includes a harpoon for engaging the piston.

Typically, the diaphragm of the cartridge is swabbed with alcohol before being loaded into a pre-sterilized syringe. As the cartridge is loaded into the syringe, the access needle extending proximally from the distal end of the barrel pierces the cartridge diaphragm so the anesthetic in the cartridge can be dispensed. Once the cartridge is in place, the plunger rod of the syringe pushes the piston of the cartridge toward the diaphragm, forcing anesthetic through the access needle, into the delivery needle, and ultimately into the patient.

To assemble the anesthetic syringe assembly the cartridge is swabbed with alcohol, the sterilized syringe is removed from its container, and the alcohol-swabbed cartridge is loaded in the barrel of the syringe. As the plunger moves distally, it forces the cartridge diaphragm onto the access needle and pushes the cartridge piston distally to force the anesthetic through the access needle, through the delivery needle, and ultimately into the patient. As will be appreciated by those skilled in the art, between each use the syringe must be sterilized, a new delivery needle must be mounted on the syringe, and a new cartridge must be prepared and loaded. This multi-step procedure takes time and is resource and labor intensive. There is a need for a syringe assembly that reduces the time, resources, and labor required to provide anesthetic to a patient.

SUMMARY

The present invention relates to a needle and receiver assembly for use with a syringe cartridge filled with medicine. The assembly includes a cartridge receiver that has a hollow interior, an open end sized for receiving at least part of the syringe cartridge, and a closed end opposite the open end. The assembly also includes a needle mounted on the receiver that has a fluid passage extending between a sharp delivery tip at a distal end of the needle adapted for inserting the needle into tissue of a patient and a sharp access tip at a proximal end of the needle opposite the delivery tip adapted for inserting the needle into a diaphragm of the cartridge, the needle extending through the closed end of the receiver so the access tip is positioned inside the hollow interior of the receiver and the delivery tip is positioned outside the receiver. The assembly also includes a cutter movably mounted in the hollow interior of the receiver for cutting the diaphragm of the cartridge when received in the hollow interior of the receiver.

The present invention further relates to a method for preparing a cartridge and a needle and receiver assembly including peeling a protective sheet from a barrier sheet on the receiver to expose adhesive. The method also includes positioning a diaphragm of a cartridge on the exposed adhesive. The method also includes actuating a cutter to remove a portion of the adhesive and diaphragm to expose a sterile area on the diaphragm; capturing the portion of the adhesive and diaphragm. The method also includes piercing the diaphragm with an access tip of a needle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of a needle and receiver assembly of a first embodiment of the present invention;

FIG. 2 is a vertical cross section of the assembly of FIG. 1;

FIGS. 3 a, 3 b, and 3 c are schematic cross sections of the assembly of FIG. 1 showing a cutter in different positions;

FIG. 4 is a perspective of a syringe cartridge adapted for use with a needle and receiver assembly of a second embodiment of the present invention;

FIGS. 5 a and 5 b are schematic cross sections of the assembly of FIG. 4 showing the cartridge in different positions;

FIG. 6 is a perspective of a cutter of an assembly of a third embodiment of the present invention; and

FIGS. 7 a and 7 b are schematic cross sections of the assembly of FIG. 4 showing the cartridge in different positions.

Corresponding reference characters indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to the drawings and more particularly to FIG. 1, a needle and cartridge receiver sub-assembly of the present invention is designated in its entirety by the reference number 10. The sub-assembly 10 includes a cartridge receiver, generally designated by 22, as shown in FIG. 1. The cartridge receiver 22 has a cylindrical wall 24 defining a hollow interior 26, an open end 28 sized for receiving part of a conventional syringe cartridge or carpule C, and a closed end 30 opposite the open end as shown in FIG. 2. The open end 28 includes a flange 32 that receives a sterile barrier film 34 having adhesive on both faces. The film 34 closes the open end 28 of the receiver 22 to maintain a sterile environment in the hollow interior 26. The diaphragm D of the cartridge C is adhesively bonded to the barrier 34. A gasket 36 is positioned inside the hollow interior 26 adjacent the closed end 30 of the receiver. A cutter or blade 40 is pivotally attached to the cylindrical wall 24 so that a sharp leading edge 42 of the cutter can rotate in the hollow interior 26, tracing a circular path as indicated by a dashed line in FIG. 2.

As further illustrated in FIG. 2, a needle 50 is mounted on the cartridge receiver 22 so that it extends through a hub 52 formed on the closed end 30 of the receiver. The needle 50 has a central fluid passage 54 (FIG. 1) extending between a sharp delivery tip 58 (shown in phantom in FIG. 1) and a sharp access tip 56 opposite the delivery tip. The delivery tip 58 is positioned at a distal end of the needle 50 and is adapted for insertion in tissue of a patient. The access tip 56 is positioned at a proximal end of the needle 50 and is adapted for piercing the diaphragm D of the cartridge C to insert the needle into the cartridge. The needle 50 extends through the closed end 30 of the receiver 22 so the access tip 56 is positioned inside the hollow interior 26 of the receiver and the delivery tip 58 is positioned outside the receiver. A removable needle sheath 60 is mounted on the needle hub 52 and covers the delivery tip 58 until ready for use to prevent inadvertent injury to medical personnel.

The cutter 40 is a generally C-shaped blade pivotally mounted on opposite sides of the receiver 22 as shown in FIG. 1. Thus, the cutter 40 is rotatably mounted on the receiver 22 for rotation about an axis A extending perpendicular to the longitudinal axis L of the needle and receiver. In one embodiment, the cutter 40 may be rotated by a crank or other actuator (not shown). As the cutter 40 rotates, it progresses through the positions shown in FIGS. 3A, 3B, and 3C. In its initial state, the cutter 40 rests generally against the gasket 36 near the closed end 30 of the receiver 22. When actuated, the cutter 40 pivots upward from the gasket 36 and gouges a generally spherical divot in the diaphragm D of the cartridge C as shown in FIG. 3 b. Continuing to rotate, the cutter 40 is buried in the gasket 36 as shown in FIG. 3C so the non-sterile slice removed from the diaphragm D is captured between the cutter and the gasket. In one embodiment, it is envisioned that a pulsing magnetic field could be applied to the cutter 40 to rotate it from the position shown in FIG. 3A, through the position shown in FIG. 3B, and to the position shown in FIG. 3C. Thus, the receiver 22 is positioned in an actuator (not shown) producing an appropriate magnetic field to prepare the needle and receiver sub-assembly 10. The sub-assembly is positioned in a barrel of a syringe and a plunger rod of the syringe is actuated to engage the piston of the cartridge.

To prepare a needle and receiver assembly for use, a protective sheet is peeled from the barrier sheet on the receiver to expose the adhesive. The diaphragm of a cartridge is positioned on the exposed adhesive. Next, the assembly is actuated so the cutter removes a portion of the adhesive and diaphragm to expose a sterile area on the diaphragm. As previously discussed, the removed portions of the adhesive and diaphragm are captured between the cutter and gasket. Once the portion of the diaphragm is removed, the cartridge is advanced toward the access tip of the needle to pierce the diaphragm.

In a second embodiment of the present invention shown in FIG. 4, the diaphragm D of the cartridge C is pre-notched by the manufacturer so the diaphragm is shipped with a frangible notch N. As illustrated in FIG. 5 a, the needle and receiver sub-assembly of the second embodiment, generally designated by 80, includes a receiver 82 having a hollow interior 84, an open end 86, and a closed end 88. The open end 86 is covered by a barrier 90 having an adhesive outer face. The closed end 88 has a hub 92 for supporting a needle 94 having a central passage not shown) extending between a sharp distal delivery tip (not shown) and a sharp proximal access tip 96 opposite the delivery tip. Rather than having a cutter, the cartridge C is applied to the sterile barrier 90 as shown in FIG. 5 a. The cartridge C is forced through the position shown in FIG. 5 b to seat the cartridge against the closed end 88 of the receiver 82. The sub-assembly is positioned in the barrel of the syringe and the plunger rod of the syringe is pushed to engage the piston of the cartridge C. As the plunger rod is pressed against the piston, pressure builds inside the cartridge causing the diaphragm to bulge and forcing the cartridge distally, stretching the sterile barrier. Both apply a radial force to the cartridge notch, tearing the diaphragm at the notch and exposing a portion of the diaphragm D. As the cartridge continues to move distally, the access tip 96 of the needle 94 pierces the newly exposed portion of the diaphragm D. The non-sterile portions of the diaphragm D are captured against the sterile barrier 90 of the sub-assembly 80 to prevent contamination of the fluid delivered through the needle 94. As other aspects of the second embodiment are similar to those of the first embodiment, the second embodiment will not be described in further detail.

A third embodiment of a needle and receiver sub-assembly of the present invention is designated in its entirety by the reference number 100 in FIG. 7 a. The sub-assembly 100 of the third embodiment is similar to that of the first embodiment except a different cutter, generally designated by 102, is mounted inside its receiver 104. The cutter 102 comprises two opposing blades 106 as shown in FIG. 6 pivotally attached to the receiver 104. The opposing blades 106 of the cutter 102 are configured such that they initially engage each other. When the plunger rod is depressed, the cartridge C moves distally into the receiver 104. The blades 106 cut through the sterile barrier and into the diaphragm D. As the cartridge continues to travel distally, the cutters separate, skiving the non-sterile surface of the diaphragm away with each cutter, exposing its internal sterile surface positioned directly above the access end of the needle. As other features of the third embodiment are similar to those of the first embodiment, they will not be described in further detail.

As will be apparent to those skilled in the art, various materials may be used to make the components of the needle and receiver sub-assemblies. For example, the needles and cutters may be made of stainless steel, and the receivers may be made of plastic. Further, the receivers may be made transparent so that flash back can be visually confirmed.

Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.

When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 

What is claimed is:
 1. A receiver assembly for use with a cartridge, said assembly comprising: a cartridge receiver having a hollow interior, an open end sized for receiving at least part of the cartridge, and a closed end opposite the open end; a needle mounted on the receiver having a fluid passage extending between a delivery tip at a distal end of the needle for inserting the needle into tissue of a patient and an access tip at a proximal end of the needle opposite the delivery tip, the needle extending through the closed end of the receiver so that the access tip is positioned inside the hollow interior of the receiver and the delivery tip is positioned outside the receiver; and wherein the access tip of the needle is positioned to be spaced from a diaphragm of the cartridge in an unbulged position of the diaphragm and to pierce the diaphragm of the cartridge in a bulged position of the diaphragm.
 2. The receiver assembly of claim 1 further including a sterile barrier between the cartridge and the hollow interior of the cartridge receiver.
 3. The receiver assembly of claim 2 wherein the sterile barrier includes an adhesive outer face.
 4. The receiver assembly of claim 2 wherein bulging of the diaphragm further causes stretching of the sterile barrier and movement of the diaphragm and sterile barrier toward the access needle.
 5. The receiver assembly of claim 2 wherein, in the bulged position of the diaphragm, the access tip of the needle pierces the sterile barrier and a notched portion of the diaphragm of the cartridge.
 6. The receiver assembly of claim 5 wherein the notched portion of the diaphragm of the cartridge is a frangible notch.
 7. The receiver assembly of claim 1 wherein, in the bulged position of the diaphragm, at least a portion of the diaphragm is captured against the sterile barrier.
 8. The receiver assembly of claim 1 wherein movement of the diaphragm from the unbulged position to the bulged position is in response to pressure on the cartridge.
 9. The receiver assembly of claim 1 wherein movement of the diaphragm from the unbulged position to the bulged position is in response to a plunger rod being pressed to engage a piston of the cartridge.
 10. A method for preparing a cartridge and a receiver assembly comprising: positioning a diaphragm of a cartridge in an unbulged configuration in a spaced apart configuration with respect to an access needle of the cartridge; and applying pressure on the cartridge, thereby causing the diaphragm of the cartridge to bulge, thereby causing the access needle to pierce the diaphragm and causing fluid communication between the cartridge and the access needle.
 11. The method of claim 10 further including the step of providing a sterile barrier between the cartridge and the receiver assembly.
 12. The method of claim 10 wherein the step of providing a sterile barrier further includes the step of providing an outer adhesive face on the sterile barrier.
 13. The method of claim 11 wherein the step of applying pressure on the cartridge further causes stretching of the sterile barrier and movement of the diaphragm and sterile barrier toward the access needle.
 14. The method of claim 10 further including the step of providing a notched portion on the diaphragm and wherein the step of applying pressure to the cartridge further causes the access tip of the needle to pierce the notched portion of the diaphragm.
 15. The method of claim 14 wherein the step of providing a notched portion further includes the step of providing a frangible notch on the diaphragm.
 16. The method of claim 11 wherein the step of applying pressure to the cartridge further causes at least a portion of the diaphragm to be captured against the sterile barrier.
 17. The method of claim 10 wherein the step of applying pressure to the cartridge further includes the step of pressing a plunger rod to engage a piston of the cartridge.
 18. A medical cartridge receiver assembly comprising: a cartridge receiver having an annular side wall extending between a partially closed distal end and an open proximal end opposing the distal end, the proximal end attachable to a medical cartridge; a hub mounted to the distal end for supporting a needle having a sharp distal tip and a sharp proximal tip; and a pierceable sterility barrier secured to the open proximal end.
 19. The medical cartridge receiver assembly of claim 18 wherein the pierceable sterility barrier includes an adhesive outer face.
 20. The medical cartridge receiver assembly of claim 18 wherein relative cooperative movement of the cartridge receiver and the medical cartridge forms a sterile fluid pathway from the medical cartridge to the sharp proximal tip. 